PARTE I - TOYOTA - Lean Manufacturing

[Music] consistently crafted cars roll off the assembly line in a smooth flow they are alive with the spirit of providing people with quality products through conscientious manufacturing and continuing research and development this is the Toyota production system where manufacturers eliminate waste to provide customers with well-made products in a timely [Music] manner at the heart of the Toyota production system are the concepts of intelligent Automation and Just in Time [Music] Manufacturing let's explore the history of that system which has transformed manufacturing around the [Music] world the concept of intelligent automation called jidoka originated in looms invented

by sakichi Toyota the founder of the Toyota group weaving traditionally had been a very manual kind of [Music] work the Weaver fed the horizontal yarn back and forth between the vertical [Music] [Applause] [Music] Yarns sakichi had watched his mother working at a manual Loom and thought of ways to make weaving [Music] [Applause] [Music] easier he invented an original wooden handloom in 1890 his Loom was easy to use and nearly 50% more efficient than previous looms the operator could move the yarn guide back and forth with one hand and feed in the horizontal yarn simultaneously sakichi

then went to work on power Looms in 1896 he created Japan's first powerloom and he continued making one Improvement after [Music] another in 1924 sakichi and his son kiichiro achieved a historic breakthrough they created the world's first high-speed Loom that fed in new WFT the horizontal yarn reliably without interrupting work let's take a look at a feature of their breakthrough non-stop Loom the model G traditional looms wasted material on fabric like this when one of the vertical warp Yarns snapped as often happened to prevent that waste sakichi and kicho arranged thin metal floaters over the

vertical Yarns a floater would slip down and stop the loom if its yarn snapped these automatic stop Innovations for preventing waste were absolutely remarkable zakii had created sophisticated sensors and he had done that without the benefit of the electrical and Optical technology we now take for granted his Innovations eliminated the need for an operator to watch over each Loom continuously one operator could oversee more than 30 looms the model G captured a great deal of attention in Europe and the United States so saki's advances resulted in machines that would stop automatically if problems occurred that

would not produce defective work and did not oblige people to serve as monitors the middle character in the Japanese word for automation jidoka is do for movement but sakichi replaced that character with one that means value added work note the additional element on the left side which represents people saki's jidoka put the human element into automation the other core Concept in the Toyota production system is Just in Time Manufacturing this concept originated in the ideas of sakii s Kido who led Toyota into automobile Manufacturing along with working with his father on the model G Loom

heicho helped put in place a mass production system he established Toyota automatic Loom Works in 1926 and introduced American assembly line methods to produce the model [Music] gum Kido traveled to Europe and North America in 1929 to find life lies for his company's automatic Loom technology he was amazed at all the vehicles and roads in the United States and he resolved to begin developing automobiles people tried to dissuade kicho they said that Japan didn't have either the technology or the economic foundation for a viable car industry but he ignored their doubts and set up a

shop in a loom Factory to develop small engines he undertook the risk of investing in expensive Precision [Music] equipment in 1935 his team created a passenger car prototype the Toyota model A1 in the following year the first Toyota passenger car went into production as the Toyota model [Music] AA Kido Incorporated his automobile operations in 19 1937 and began work on a vehicle [Music] plant he refined American mass production methods for his plant and developed the beginnings of Just in Time [Music] Manufacturing the idea was to eliminate waste by making only what was needed only when

it was needed and only in the amount needed making Quality Cars of satisfactory performance required an allout effort and Kido was moving to refine Just in Time Manufacturing further but the outbreak of World War II in 1941 interrupted his efforts